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ENKOFLEX Horizontal Formwork Construcción IMPORTANT: Any safety provisions as directed by the appropriate governing agencies must be observed when using our products. The pictures in this brochure are snapshots of situations at different stages of assembly, and therefore are not complete images. For the purpose of safety, they should not be deemed as definitive. All of the indications regarding safety and operations contained in this brochure, and the data on stress and loads should be respected. ULMA Construcción’s Technical Department must be consulted anytime that field changes alter our equipment installation drawings. Our equipment is designed to work with accessories and elements made by our company only. Combining such equipment with other systems is not only dangerous but also voids any or all our warrantees. The company reserves the right to introduce any modifications deemed necessary for the technical development of the product. All rights reserved Neither all nor part of this document may be reproduced or transmitted in any way by any electronic or mechanical procedure, including photocopy, magnetic recording or any other form of information storage or retrieval system without the written permission of ULMA Construcción. ENKOFLEX Horizontal Formwork 4 6 12 18 21 22 24 26 36 40 Objective Product description Assembly and disassembly Technical solutions Safety Elements Applications Receiving, storing and cleaning Components and accessories ULMA Construcción addresses Our Products ENKOFLEX Horizontal Formwork Objective The objective of this document is to provide the reader with information on our ENKOFLEX horizontal formwork systems. In the first part of the manual, we provide a product description, especially focused on the shuttering face and on the shoring systems used with this product. Additionally, basic product assembly and disassembly are explained in this manual. The Technical Solutions section expounds on system options offered as solutions for the different cases that may occur on the construction site. Then, the manual explains how to assure the safe use of the system, and it expounds on the safety components used in the system. The section on Receiving, Storing and Cleaning the system describes how to properly stack components for transporting or simply moving the parts used in the ENKOFLEX horizontal formwork. Following that, there is a complete list of Components and Accessories, providing the names and drawings with dimensions. For an in depth on the proper functionality, use and handling of the ENKOFLEX Horizontal Formwork system, it is recommended to read the ENKOFLEX User's Manual. Also, remember that you can contact the technical support personal in the Engineering Department of the ULMA branch office closest to the construction site. As always, we are here to serve you. 4 Construcción 5 Construcción ENKOFLEX Horizontal Formwork Product description ENKOFLEX is a horizontal formwork system designed for any type of slab formwork, whether solid or lightened (except those with domes) as well as for drop beams or other elements. As it is a formwork made up of independent beams, the system is highly versatile, enabling it to suitably adapt to irregular slabs. It is also the ideal system for infillings and areas that are not covered with other formwork systems, such as the VR Tables or CC-4. The main system components are the following: VM 20 Beams VR Simple Head VR Double Head Board 6 Construcción ENKOFLEX Horizontal Formwork VM 20 Beams VR Simple Head This part is used to build the ENKOFLEX system's grid. VM 20 Beams can be used as main or secondary beams. This is used to shore the VM 20 Main Beams in the ENKOFLEX system. The VR Simple Head can be mounted on all of the ULMA Construcción Props. The timber Beams are in the shape of a double "T": 200 mm long by 80 mm wide. The two ends are protected by plastic pieces. The Head's open profile facilitates its assembly and disassembly. It can be fixed to the EP Props using the pin and a Cotter Pin. VM Beams are available in different lengths, so that the most appropriate length can be chosen for each case. VM 20 Beam properties are shown below: VR Double Head • Maximum admissible bending moment: 5.0 kNm • Admissible shear force: 11 kN • Stiffness (EI): 450 kNm2 The Head socket incorporates Ø 18mm pre-tapped holes for inserting Pins. As with the VR Simple Head, it can be fixed to the EP Props using pin Ø16x100 and Cotter Pin 3. Board Depending on the Board selected, the distance between the secondary beams and the deformation criteria, the maximum possible slab thickness is calculated. 7 Construcción ENKOFLEX Horizontal Formwork Beto 18 7 Spans 6 Spans 5 Spans 4 Spans 7 Spans 6 Spans 5 Spans 4 Spans 6 Spans 5 Spans 4 Spans 3 Spans 6 Spans 5 Spans 4 Spans 3 Spans Beto 21 3-Ply Sheet 21 3-Ply Sheet 27 Maximum slab thickness (m) according to ULS or SLS criteria. 8 Construcción ENKOFLEX Horizontal Formwork Working Load Tables Once the slab thickness and the Board to be used are known (according to resistance, the span of the VM 20 Secondary Beams and the required concrete finish), this is checked on the use table, calculating the maximum distance between VM 20 Main Beams. Once the maximum distance between VM 20 Main Beams is known, the maximum distance between props is selected. Depending on the height at the construction site, the appropriate prop must be selected to support the formwork loads. ENKOFLEX system use table for Beto Board. Due to the load bearing limitations of the VM 20 Beam, the Prop must never be used to support loads greater than 20 kN. 9 Construcción ENKOFLEX Horizontal Formwork Due to the load bearing limitations of the VM 20 Beam, the Prop must never be used to support loads greater than 20 kN. This data applies to new Props that are plumbed and supporting a centered vertical load. 10 Construcción ENKOFLEX Horizontal Formwork The following table shows the working loads obtained by calculation according to EN 1065, when EP Props are used with ENKOFLEX formwork. The use of EP Props with Rapid and Recub with the Inner Tube below is not allowed 11 Construcción ENKOFLEX Horizontal Formwork Assembly instructions Basic assembly For more information, see the ENKOFLEX Horizontal Formwork User's Manual The ENKOFLEX system's basic assembly comprises VM 20 Beams forming two layers, supported by VR Two-Way U-Heads and VR Simple Heads. The board is supported by the VM 20 Secondary Beams. The Two-Way U-Heads are assembled on both ends of each main beam, as well as where the VM 20 Main Beams overlap. The Props with VR Two-Way U-Heads are assembled with Tripods to give the system stability. ENKOFLEX system’s basic assembly 12 Construcción ENKOFLEX Horizontal Formwork 1 Insert the Head in the upper side of the Prop. 2 Lay out the main beams in accordance with the drawing. Place the props, stabilizing them with tripods and following the layout lines. 3 Place the main beams, shoring each one with two Props and Two-Way U-Heads on their ends. Use Tripods to stabilize them. Place the intermediate props with the Simple Head. The main beams shall be mounted with the help of specific components required, or in their absence with auxiliary equipment. 13 Construcción ENKOFLEX Horizontal Formwork 4 Place the secondary beams leaving the distance indicated in the assembly drawings. When placing the secondary beams, use the same equipment used to place the main beams. 5 Install the Boards and secure it. The operator must be tied off at all times using an anti-fall harness with securing shackle tied to the lifeline that is installed between the columns or using auxiliary safety measures. 6 Close off the perimeter using Handrails and Toe boards. 14 Construcción ENKOFLEX Horizontal Formwork Disassembly instructions Basic Disassembly Once the concrete has cured to the necessary hardness, proceed to stripp the formwork. 1 Remove the perimeter protections and place them in the slab previously poured. 2 Remove all Intermediate Props with Simple Heads. Study the stripping process in order to avoid overloading the Props. When removing the Props, it is not necessary to completely extract the Simple Head from the Prop. It is sufficient to loosen it and rotate it to the side. 15 Construcción ENKOFLEX Horizontal Formwork 3 Loosen the remaining Props approximately 5 cm in order to drop the main beams. Take the necessary precautions to assure that none of the components fall. 4 Turn the secondary beams on the main beams to remove them, leaving those that go on the panel joints. 5 Remove the panels and the secondary beams that were shoring them. 16 Construcción ENKOFLEX Horizontal Formwork 6 Strip the rest of the formwork: Main Beams, Props, Double Heads and Tripods. Removing Falsework The formwork should always be stripped from the center of the span working out. Likewise, in the case of cantilevers, the formwork should be stripped starting from the end of the cantilever and working in. Depending on the execution deadlines, layout of the formwork, thickness of the slab and total height, when the concrete can support the stresses to which it is subjected the shoring will be removed, starting with the central Props and working out towards the columns. 17 Construcción ENKOFLEX Horizontal Formwork Technical solutions Interference with Columns Once the direction of the VM 20 Main Beams has been selected, the entire slab is covered with the ENKOFLEX system. It is highly probable that some columns interfere with the formwork standard layout in this situation. Some of the most common cases are shown below: MAIN BEAMS INTERFERE WITH A COLUMN In this case, as shown in the image below, auxiliary beams are placed on both sides of the column, parallel to the main beams, enabling the secondary beam to rest on them. These auxiliary beams are supported using VR Two-Way U-Heads and Tripods. Solution for column interference with main beams. COLUMN BETWEEN MAIN BEAMS When interference with the secondary beams is inevitable, the procedure shall be the same as in the previous case. Solution for column interference with secondary beams. 18 Construcción ENKOFLEX Horizontal Formwork Infilling To make the ENKOFLEX infillings on inclined walls, the VM 20 Beam must be placed parallel to the wall, enabling the VM 20 secondary beams or the board infilling to be shored against the wall. In one case VM 20 Beam will be placed at the height of the main beams, while in the other, it will be placed at the height of the secondary beams. ENKOFLEX infilling on inclined wall: secondary beams shored on the beam against the wall. The solution depends on the angle formed between the main beam and the wall. ENKOFLEX infilling on inclined wall: board shored on the beam against the wall. 19 Construcción ENKOFLEX Horizontal Formwork Hanging beams To provide a solution for hanging beams, the main beam is placed in the main direction of the hanging beams, and the secondary beams rest on these. Hanging beam solutions with ENKOFLEX. Special attention must be paid when the hanging beam is on the perimeter of the formwork, due to the risk of overturning the assembly. It is recommended to use a VR Chain. It is recommended to use Tripods on the first Props. If the infilling is placed from above, the operator should be tied off to a life line at all times. It is necessary to anchor the formwork that is installed around the border of the slab in order to assure it cannot turn over or loose stability due to the forces of the wind. Hanging beam on the perimeter of the slab with ENKOFLEX system. 20 Construcción ENKOFLEX Horizontal Formwork Safety Elements Handrail support The Handrail Support is tied to VM 20 Beams using two Short Pins 0.35 and Hexagonal Nuts 15. It can be assembled on the main beams and on the secondary beams. The Safety Handrail Post acts as a support for mounting the front and lateral handrails. It is fixed using a Pin Ø14 and the corresponding Cotter Pin 3. In the lower section it has a sliding L in which the toe board can be placed. The Ledgers are fixed to the Safety Handrail Post using clamps with wedges, and they protect the formwork perimeter. Assembling the Handrail Support. Chain VR Assembling the Handrail. This part is used to tie the perimeter VM 20 Beams of the ENKOFLEX system (particularly those of the overhang) to the slab and thus prevent them from swinging outwards or lifting up in the event of a strong wind. It is made up of two metal chains (DIN 763) with two hooks on the ends of each chain. These chains are joined by turnbuckle M-12 eye and hook (DIN 1480). The chain is tied to the slab by a ring or screw that will have been previously placed in the slab. The chain is 5.2 m long and has a working load of 2.5 kN. 21 Construcción ENKOFLEX Horizontal Formwork Applications Infilling on column Fest City, Dubai 22 Construcción ENKOFLEX Horizontal Formwork Infilling on wall Shopping Mall (Frankfurt) 23 Construcción ENKOFLEX Horizontal Formwork Receiving, storing and cleaning RECEIVING MATERIAL ON SITE • Fence off, close off and mark off the work area, when necessary. • Receive transport vehicles on site after obtaining the necessary permits when applicable. • A priori, the storage zone will be established and duly marked. UNLOADING MATERIAL Mechanical unload • All the material will arrive grouped and strapped. • The person in charge of receiving the material will revise the condition of the pallets or packages. • The forklift route will be marked in order to avoid interferences with personnel. • The forklift operator will store the materials following the operator instructions provided by the person in charge of storage. • In no case shall the operator in charge of storage or receiving, loiter in the forklift travel route. Unload with crane • The operator in charge of unloading shall not loiter underneath the load. NO • The operator will wait until the load is practically on the ground before guiding it to the proper place. Manual unload • Loads of greater than 25 kg will not be handled by a single person. 24 Construcción ENKOFLEX Horizontal Formwork STORAGE EP Props are supplied on the corresponding pallet. After they have been used at the construction site, the Props should be piled on said pallet, stacking them in both directions in order to balance the load. After they are stacked, they should be strapped down. The Boards and Beams should be strapped. Other elements are supplied in bulk in boxes or pallets. System components should always be stored after they have been cleaned and after each time they have been put up. Boards should always be stacked off the ground, on leveled supports and under a covered roof. Exposing to prolonged periods of sunlight or rain can damage the boards. LIFTING AND MOVING MATERIALS The biggest components will be lifted or lowered with a hoist to the different floors (or levels) in packages that are strapped on both ends; the materials will be suspended from a set of slings strapped to the tower crane hook. All other elements will be moved in boxes. CLEANING The formwork surfaces should be checked and cleaned before placing the materials that comprise the structure. Boards should be cleaned after each use with a brush and a release agent. Do not use wire brushes that can damage the board surface. 25 Construcción ENKOFLEX Horizontal Formwork Components and accessories Basic Elements VM 20 Beam Beam VM 20/1.9 Beam VM 20/2.45 Beam VM 20/3.9 Beam VM 20/4.9 Beam Beam Beam Beam VR Simple Head VR Double Head VM VM VM VM 20/2.9 20/3.3 20/3.6 20/5.9 WEIGHT (kg) CODE L (mm) 9.5 12.25 19.5 24.5 1940172 1950129 1950112 1950113 1900 2450 3900 4900 14.5 16.5 18 29.5 1940144 1950130 1940146 1940149 2900 3300 3600 5900 WEIGHT (kg) CODE 0.72 2211000 WEIGHT (kg) CODE 4.78 2211003 26 Construcción ENKOFLEX Horizontal Formwork Boards Beto Board 1.25x2.5x0.021 Beto Board 1.25x2.5x0.018 Beto 3-Ply Sheet 3-Ply Sheet 2000x503x21 3-Ply Sheet 2000x503x27 WEIGHT (kg) CODE X (mm) 40.7 34.9 1940166 1940198 21 18 WEIGHT (kg) CODE X (mm) 11.4 15 7251131 7251132 21 27 27 Construcción ENKOFLEX Horizontal Formwork VM Handrail Support Short Pin 0.35 WEIGHT (kg) CODE 6.9 2211165 WEIGHT (kg) CODE 0.6 1861033 DW 15 Safety Elements 350 WEIGHT (kg) CODE 0.22 7238001 50 Hexagonal Nut 15 Ø36 28 Construcción ENKOFLEX Horizontal Formwork Safety Handrail S-V Safety Handrail 1.50 WEIGHT (kg) CODE 3.9 1860516 WEIGHT (kg) CODE 9.6 2211156 Clamp Safety Handrail WEIGHT (kg) CODE 5.6 1860723 500 1815 1690 500 ø50 29 Construcción ENKOFLEX Horizontal Formwork Tube 42/4070 with Socket Tube 42 Tube 42/1.55 Tube 42/2.1 Tube 42/3.1 Tube 42/4.1 Tube 42/5 WEIGHT (kg) CODE 8.4 2023800 WEIGHT (kg) CODE L (mm) 3 4.1 6.4 8.4 12.2 2033700 2033800 2034000 2033600 2053000 1550 2100 3100 4100 5000 30 Construcción ENKOFLEX Horizontal Formwork Tube Ø48 WEIGHT (kg) Tube 48/4100 with Socket CODE 5.5 7 8.7 11.4 12.1 14.6 18 2125290 2125291 2125647 2125249 2125648 2125250 2125251 WEIGHT (kg) CODE 13.14 2125649 4100 ø 48 Tube 48/1.6 Tube 48/2.1 Tube 48/2.6 Tube 48/3.1 Tube 48/3.6 Tube 48/4.1 Tube 48/5 31 Construcción ENKOFLEX Horizontal Formwork Plastic Handrail Support Plug 42 WEIGHT (kg) CODE 0.1 1860533 WEIGHT (kg) CODE 0.007 1904100 44 VR Chain WEIGHT (kg) CODE 2.9 2211035 16,5 55 5200 32 Construcción ENKOFLEX Horizontal Formwork VR Chain anchoring elements Eyebolt Screw M16 Ring 12x120 Ring 12x160 Ring 12x230 HKD Hilti Plug M16 Plastic Plug 14x70 Plastic Plug 14x100 Plastic Plug 14x140 WEIGHT (kg) CODE 0.3 0.18 0.22 0.29 0.9 0.01 0.01 0.01 9165400 9371772 9371778 9371779 9850530 9371777 9371774 9371773 WEIGHT (kg) CODE 2.86 2211051 Other Components VR Fork 33 Construcción ENKOFLEX Horizontal Formwork Shoring Elements SP Prop Normal Prop 1.75/3.1 Normal Prop 2.1/3.5 Strong Prop 2.1/3.65 Strong Prop 2.35/4 Strong Prop 3.65/5.25 SP-40 Prop SP-50 Prop CODE H (m) WEIGHT (kg) Ø d (mm) Ø D (mm) 2150000 2150500 2154300 2159333 2154400 2170400 2170500 1.75-3.1 2.1-3.5 2.1-3.65 2.35-4 3.65-5.25 2.5-4.00 3.9-5.00 10 10.6 13.6 15.1 18.8 16.3 23.1 40 40 52 52 52 54 64 48 48 60 60 60 66 76 34 Construcción ENKOFLEX Horizontal Formwork Universal Tripod CODE L max. L min. 14.6 16.5 21.2 23.7 29.1 31.7 18.9 26.4 2200048 2200000 2200068 2200012 2200084 2200057 2200023 2200033 2500 3000 3500 4000 4500 5000 3000 4000 1477 1722 1974 2222 2477 2730 1722 2222 WEIGHT (kg) CODE 11.2 2220090 0 12 120 EP Prop C25 EP Prop C+D30 EP Prop C+D35 EP Prop C+D40 EP Prop C+D45 EP Prop C+D50 EP Prop C+E30 EP Prop C+E40 WEIGHT (kg) 780 EP Prop 35 Construcción Production Plant ULMA C y E, S. Coop. Ps. Otadui, 3 - P.O. Box 13 20560 OÑATI (Guipúzcoa) SPAIN Phone: +34 943 034900 Fax: +34 943 034920 Web: www.ulma-c.com ULMA Worldwide EUROPE Germany ULMA Betonschalungen und Gerüste GmbH Kronberger Str. 16 D-63110 RODGAU-DUDENHOFEN Phone: +49 6106 28677 0 Fax: +49 6106 28677 86 Noroeste Branch Stresemannallee 4c D-41460 NEUSS Phone: +49 2131 40201 0 Fax: +49 2131 40201 99 Sudoeste Branch Manfred - Wörner - Str. 115 D-73037 GÖPPINGEN Phone: +49 7161 50608 42 Fax: +49 7161 50608 43 France ULMA, S.A.R.L. 27, rue Gustave Eiffel Z.I. de la Marinière 91070 BONDOUFLE Phone: + 33 1 69 11 54 50 Fax: + 33 1 69 11 54 54 IDF Échafaudages Branch 22 Bis, rue Gustave Eiffel Z.I. de la Marinière 91070 BONDOUFLE Phone: + 33 1 69 11 63 30 Fax: + 33 1 69 11 63 31 IDF Construction Branch 27, rue Gustave Eiffel Z.I. de la Marinière 91070 BONDOUFLE Phone: + 33 1 69 11 63 40 Fax: + 33 1 69 11 63 37 Eguilles Branch 50, allée Meulière Z.I. – Route de Berre 13510 EGUILLES Phone: + 33 4 42 64 62 30 Fax: + 33 4 42 64 62 31 Saint Herblain Branch 11, rue Fondeur Z.I. du Tisserand 44800 SAINT HERBLAIN Phone: + 33 2 51 80 48 04 Fax: + 33 2 51 80 48 05 La Chapelle d’Armentières Branch Zone Industrielle Rue André Ampère 59930 LA CHAPELLE D’ARMENTIÈRES Phone: + 33 3 20 07 11 86 Fax: + 33 3 20 07 11 68 Tarnos Branch 40, rue de l’Industrie Z.I. de Tarnos 40220 TARNOS Phone: + 33 5 59 64 44 45 Fax: + 33 5 59 64 44 84 Italy ALPI, S.P.A. 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Ind. de Roces, 5 Gustavo Eiffel, 46 33211 GIJÓN (Asturias) Phone: 98 5168038 Fax: 98 5167513 GALICIA Branch Pol. Ind. Espíritu Santo Rua Bell, 24-26 15650 CAMBRE (La Coruña) Phone: 981 649802 Fax: 981 649060 MURCIA Branch Pol. Ind. La Serreta Calí, s/n 30500 MOLINA DE SEGURA (Murcia) Phone: 968 642679 Fax: 968 641276 BALEARES Branch Pol. Ind. Son Noguera Cas Rossos, 12-14 07620 LLUCMAJOR (Illes Balears) Phone: 971 669850 Fax: 971 121512 GRANADA Branch Camino Nuevo, s/n 18210 PELIGROS (Granada) Phone: 958 405028 Fax: 958 405328 NORTE Branch Pol. Ind. Goiain Av. San Blas, 1 01170 LEGUTIANO (Álava) Phone: 945 001100 Fax: 945 001111 BARCELONA Branch Pol. Ind. Sud - Est Pintor Velázquez, 7 y 9 08213 POLINYA (Barcelona) Phone: 93 7132727 Fax: 93 7133643 LAS PALMAS Branch Pol. Ind. Las Majoreras Los Llanillos, 33 35259 INGENIO (Las Palmas) Phone: 928 789212 Fax: 928 789538 SEVILLA Branch Pol. Ind. Fridex Autovía Sevilla - Málaga, km 4,2 41500 ALCALÁ DE GUADAIRA (Sevilla) Phone: 95 5630044 Fax: 95 5630020 CASTILLA - LEÓN Branch Ctra. Burgos - Portugal, km 116 47270 CIGALES (Valladolid) Phone: 983 581009 Fax: 983 581021 MADRID Branch Pol. Ind. Sur 28863 COBEÑA (Madrid) Phone: 91 6523199 Fax: 91 6528828 TENERIFE Branch Pol. Ind. Valle de Güimar Manzana XIII - Parcelas 21 y 22 38509 GÜIMAR (Tenerife) Phone: 922 505020 Fax: 922 501101 VALENCIA Branch Pol. Ind. Los Vientos Gregal, 7 (Apdo. 96 Moncada) 46119 NÁQUERA (Valencia) Phone: 96 1399130 Fax: 96 1399096 39 Construcción ENKOFLEX Horizontal Formwork Our Products Vertical Formworks ORMA Modular Formwork A system for large works and high performance Circular Sheet Formwork BIRA Formwork system designed for circular wall configurations ENKOFORM V-100 Bracing System Wall and Column Formwork with Steel Walers and Timber Beams LGR Column Formwork Column formwork using light panels COMAIN Hand-held Formwork Modular Formwork that is light and easy to handle by a single person CLR Circular Column Formwork Circular column formwork, designed to solve the different column diameters easily NEVI Modular Formwork Vertical handset and gang formwork system Formwork Climbing Systems Climbing and self-climbing systems for any height 40 Construcción ENKOFLEX Horizontal Formwork Horizontal Formworks RAPID Reusable Formwork Formwork that can be easily and quickly recovered from assembly VR Work Table Horizontal formwork for any forging type RECUB Reusable Coffer Formwork Speed and safety in assembly and removal ENKOFLEX Formwork Horizontal formwork for wooden beams, easy to assemble and very versatile ENKOFORM H-120 Bracing System A multipurpose system, capable of resolving the diverse types of construction work Wood Panels for Formwork Panels that adhere to the highest of site demands CC-4 Horizontal Formwork Aluminium horizontal formwork, light, fast setting and stripping 41 Construcción ENKOFLEX Horizontal Formwork Our Products Props and Shoring SP Prop Special design for regulating and securing at heights, light and easy to handle G Shoring Easy, effective system for shoring horizontal formworking EP Prop The post shore that offers the best features for easy operation and fast stripping T-60 Shoring Frame shoring, fast assembly and easy to use ALUPROP Aluminium Prop Light and with high load capacity OC Shoring Post shoring, sturdy, safe and with great flexibility of deployment DORPA Façade Scaffolding High-performance modular system for covering façades BRIO-ST Façade Stabiliser Combination of sturdiness, simplicity and safety Scaffoldings The Modular BRIO Versatile system capable of covering all possible configurations and applications 42 Construcción ECEL05